Seat module for cable arrangement

ABSTRACT

A seat module adapted to be attached to a seat having component for seat actuation in a motor vehicle includes at least one operating cable, and a module plate formed with a mounting feature for attaching to the seat and a retention feature for retaining at least one operating cable. Further, the operating cable is retained in the module plate in a pre-assembled state where the operating cable is retained by the module plate in a stowed condition, and the operating cable is released from the stowed condition and connected to the components of the seat in an assembled state where the module plate retaining the operating cable is attached to the seat.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.16/998,538 filed on Aug. 20, 2020, entitled “SEAT MODULE FOR CABLEARRANGEMENT,” the entire contents of which are incorporated herein byreference.

TECHNICAL FIELD

This present disclosure relates to a seat module that retains mechanicalcontrol cables for seat actuation potentially suited for variousapplication but in a preferred implementation utilized in an automotiveseat assembly.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Mechanical control cables for seat actuation are directly mounted to aseat frame in an automotive seat. Each of the mechanical control cablesis routed one by one when they are connected to mechanical parts such aslevers or latch systems in the automotive seat. For example, in anordinary conventional seat of a motor vehicle, each of the mechanicalcontrol cables is individually fastened to a bracket by binder memberssuch as zip ties or adhesive tapes for retaining the mechanical controlcables in their routed positions. Thus, each of the mechanical controlcables is independently retained in a seat frame with its predeterminedshape respectively.

The conventional seat assembly with the mechanical control cablesrequires a large number of brackets and binder members for retaining thecables to the seat frame, and a bothersome operation of attaching manycomponents to the seat frame such that the seat assembly is a long andawkward assembly process with greater variability. For example, changesin the position of the mechanical control cable conduit affect thelength of a core wire within each of the mechanical control cables. Ifthe core wire is too short or too long when the mechanical controlcables are attached to the seat frame, seat actuation may not beachievable so that the mechanical control cables need to be rerouted andreattached. This is a disadvantage for the conventional assembly processof the seat with the mechanical control cables.

In addition, it is necessary to attach the mechanical control cables tothe lower part of the seat through a limited space enclosed by seatrails, metal brackets, various mechanism components, and alreadyattached mechanical parts. Therefore, longer working process for theattachment and many numbers of parts including binder members are neededfor connecting the mechanical control cables to the mechanical parts.Especially in attachment of the mechanical control cables to the lowerpart of the seat, the mechanical control cables have many penetratedarranging spots, and furthermore need to be arranged within the limitedspace as described above. For this reason, poor arranging workabilitywill be presented, causing possible damage by involvement of themechanical control cables, etc.

As described above, the ordinary seat assembly with the mechanicalcontrol cable includes the retaining members such as brackets orzip-ties for attaching the cables to the seat frame. The ordinary seatassembly with the retaining elements for the mechanical control cableswill have more manufacturing steps. Accordingly, there is constantly adesire to simplify the assembled components and steps of the ordinaryseat assemblies with the mechanical control cables. In addition, thereis more desire to reduce cost and weight of automotive components, whileproviding a desirable durability, low warranty claims, and compliancewith performance requirements.

SUMMARY

The present disclosure relates to a seat module retaining mechanicalcontrol cables utilized in an automotive seat assembly. In particular,the present disclosure relates to the seat module temporarily stowingoperating cables such as mechanical control cables in a pre-assembledstate, and the stowed mechanical control cables are released andconnected to seat components such as mechanical parts for the seatactuation in an assembled state after the seat module is securelymounted to the seat.

By using the seat module, the mechanical control cables could be shippedto the customer in the pre-assembled state in their routed condition byretaining the cables to a module plate. In the pre-assembled state,furthermore, the loose cable end portions would be temporarily stowedprior to shipment to reduce tangling and improve assembly at thecustomer. The customer would snap the seat module to the seat frame withthe cable end portions, which are still stowed in the module plate. Thenthe customer un-stows the cable end portions and connects the cable endportions to the mechanical parts such as frame levers and latches asneeded in the assembled state. This would eliminate the need forattaching brackets and zip ties for retaining the cables to the seatframes. In addition, repeatability of routing is greatly improved, andalso ensuring seat actuation is achieved.

According to an aspect of the present disclosure, the seat moduleattached to the automotive seat having the mechanical parts for seatactuation in a motor vehicle includes at least one mechanical controlcable for the seat actuation and a module plate formed with a mountingfeature for attaching to the seat and a retention feature for attachingthe mechanical control cable. An end portion of the mechanical controlcable is temporarily stowed on the module plate in a pre-assembled statewhere the mechanical control cable is attached to the module plate andthe end portion of the mechanical control cable is connected to themechanical parts of the seat in an assembled state where the moduleplate with the attached mechanical control cable is securely mounted tothe seat.

According to a further aspect of the present disclosure, the end portionof the mechanical control cable stowed in the pre-assembled state isretained in the module plate while the module plate is mounted to theseat and is released for connecting to the mechanical parts of the seatin the assembled state of the module plate.

According to a further aspect of the present disclosure, the retentionfeature is formed as a mechanical-lock type and located in at least onelocation of the module plate for retaining at least one portion of themechanical control cable. In addition, the retention feature isconfigured to position the mechanical control cables in a correctlocation for reducing positioning variation of the mechanical controlcables in the assembled state.

According to a further aspect of the present disclosure, the moduleplate includes a stowing feature formed and located in at least onelocation of the module plate for temporarily retaining the end portionof the mechanical control cable in the pre-assembled state and allowingthe end portion of the mechanical control cable to be released forconnecting to the mechanical parts of the seat in the assembled state.The stowing feature is formed with a mechanical-lock type for releasablyretaining the end portion of the mechanical control cable.

According to a further aspect of the present disclosure, the end portionof the mechanical control cable is temporarily stowed by tucking underor above one of the mechanical control cables on the module plate in thepre-assembled state. Each of the mechanical control cables includes apad, an adjuster, a spring, or any control cable components.

According to a further aspect of the present disclosure, the moduleplate further includes a loom protruding from a side of the module plateand being located in at least one location on the module plate. The loomis configured to retain a portion of a long looped mechanical controlcable.

According to a further aspect of the present disclosure, the moduleplate is formed of a resin material or a composite material such as aglass woven plastic composite sheet.

According to a further aspect of the present disclosure, the seat moduleincludes additional components retained in the module plate foractuating a power mechanism of the seat.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which:

FIG. 1 shows a plan view of a seat module attached to a cushion frame inan automotive seat in accordance with an embodiment of the presentdisclosure;

FIG. 2 shows a plan view of a module plate in the seat module of FIG. 1, and FIGS. 2A and 2B show detailed views of stowing features of themodule plate of FIG. 2 ;

FIG. 3 shows a plan view of mechanical control cables routed andretained in the module plate of FIG. 2 , and FIG. 3A shows a seatactuator for attaching to the module plate of FIG. 3 ;

FIG. 4 shows a plan view of the seat module in a pre-assembled state inaccordance with an embodiment of the present disclosure, FIG. 4A shows adetailed view of an end of the mechanical control cable stowed by astowing feature formed in the module plate of FIG. 4 , FIG. 4B shows adetailed view of an end of the mechanical control cable stowed bytucking in the seat module of FIG. 4 , FIG. 4C shows a detailed view ofa clip for attaching to the module plate; and FIG. 4D shows a detailedview of an adjuster and a spring element assembled with the mechanicalcontrol cable; and

FIG. 5 shows a plan view of a loom protruding from the module plate ofFIG. 2 , and FIG. 5A shows a detailed view of the loom of FIG. 5 .

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

FIG. 1 shows a lower part of a seat unit 10 for a motor vehicle. Theseat unit 10 typically includes a pair of rails 12 adapted to be fixedto a floor panel (not shown) of the motor vehicle for back-and-forthmotion and a seat cushion (not shown) attached to a cushion frame 14 forup-and-down motion, a seatback (not shown) attached to the cushion frame14 above the rails 12, and mechanical parts 16 such as levers or latchsystems coupled to the movable sections of the seat unit 10. Themechanical parts 16 are generally attached to the cushion frame 14 foradjusting the seat position and actuated by connected mechanical controlcables 104. The seat unit 10 is generally designed to move the seatcushion backward, forward, upward, and downward with respect to thefloor panel, and to cause the seatback to recline. The seat unit 10further includes a seat module 100 attached to the cushion frame 14.

In FIG. 1 , the seat module 100 includes a module plate 102 and at leastone mechanical control cable 104. Generally, more than one mechanicalcontrol cables 104 are bundled together by a cable bundle housing 106,which is attached to the module plate 102, or each of the mechanicalcontrol cables 104 is individually attached to the module plate 102without the cable bundle housing 106. As shown in FIG. 1 , the seatmodule 100 is securely mounted to the cushion frame 14 under the seatcushion for controlling the mechanical parts 16, which were alreadyinstalled to the seat unit 10 before the seat module 100 is attached tothe cushion frame 14. The attached seat module 100 actuates the drive ofthe movable portions of the seat unit 10 such as a seat-cushion positionand a reclining angle, which is mounted on the floor panel of thevehicle. In the seat unit 10, for example, the mechanical parts 16 foruse with the seat module 100 having the mechanical control cables 104are the levers and latch mechanisms associated with seat adjustment.

FIG. 2 illustrates the module plate 102 designed to fit within the givenpackaging space under the seat cushion and fixed to the cushion frame 14of the seat unit 10. The structure, dimension, shape, material, andnumber of pieces, etc. of the module plate 102 are not particularlylimited. In addition, the module plate 102 is generally made of a resinmaterial. The resin material is not particularly limited, and variousresin materials may be used. According to an exemplary form of thepresent disclosure, the module plate 102 of the seat module 100 isformed with a glass filled resin such as a Polypropylene (PP) or aPolyamide (PA), etc. The module plate 102 formed with the PP or PA hasbenefits for easy assembly and repeatability when the seat module 100 isattached to the seat unit 10.

According to other form of the present disclosure, the module plate 102of the seat module 100 is also formed of a composite material such as aglass woven plastic composite sheet (ex. an organo sheet). Inparticular, when the seat module 100 formed of the glass woven plasticcomposite sheet is attached to the seat unit 10, the module plate 102 isitself structurally used in the seat unit 10 instead of metal componentswhich structurally strengthening the seat unit 10. Accordingly, themodule plate 102 with the attached mechanical control cables 104 alsostructurally supports the seat unit 10 in addition to providing with theorganized mechanical control cables 104 for the seat actuation.

In FIGS. 1 and 2 , the module plate 102 of the seat module 100 isattached to the cushion frame 14 of the seat unit 10 via a mountingfeature 108, which is formed in multiple locations in the module plate102. According to an exemplary form of the present disclosure, themounting feature 108 is formed as a mechanical-lock type such as asnap-fit or a press-fit for allowing the seat module 100 to be securelymounted to the cushion frame 14 of the seat unit 10. In FIGS. 1 and 2 ,for example, the mounting features 108 are located in three (3)locations for attaching the seat module 100 to the cushion frame 14 ofthe seat unit 10. However, the mounting features 108 may be formed withother types such as a rivet according to other forms of the presentdisclosure. Due to the mounting features 108 formed in the module plate102, the seat module 100 with the mechanical control cables 104 issecurely mounted to the cushion frame 14 of the seat unit 10 for theseat actuation. In addition, as shown in FIG. 2 , the module plate 102includes a holding feature 109 for attaching additional components suchas a seat actuator 118 (see FIG. 3A) or a wire harness, etc. Theattached seat actuator 118 is configured to electrically control oradjust the seat position with a power mechanism 18 installed in the seatunit 10.

In FIG. 2 , the module plate 102 further includes a retention feature110. The retention feature 110 is located in multiple locations of themodule plate 102 for retaining the mechanical control cables 104, whichare routed and attached to the module plate 102. As shown in FIGS. 2 and3 , the retention features 110 are formed as a mechanical-lock type suchas a snap-fit or a press-fit for retaining a portion of the mechanicalcontrol cables 104 when each of the mechanical control cables 104 isrouted on the module plate 102. The retention feature 110 of the moduleplate 102 is configured to position the mechanical control cables 104 ina correct location for reducing positioning variation of the mechanicalcontrol cables 104 when the seat module 100 is assembled with the seatunit 10. Referring to FIG. 4 , each of the mechanical control cables 104includes an end portion 112 for connecting to the mechanical parts suchas levers or latch systems already installed in the seat unit 10 beforethe seat module 100 is attached. After the seat module 100 is attachedto the seat unit 10, the end portion 112 of each of the mechanicalcontrol cables 104 is connected to the mechanical parts 16 respectivelyand the connected mechanical control cables 104 actuate the mechanicalparts 16 of the seat unit 10 for controlling the seat movement.

As shown in FIGS. 2, 2A, 2B and 4 , the module plate 102 furtherincludes a stowing feature 114 for temporarily retaining the end portion112 of each of the mechanical control cables 104 in a pre-assembledstate where the mechanical control cables 104 are attached (retained) tothe module plate 102. In the pre-assembled state of the seat module 100,as shown in FIGS. 1 and 4 , the end portions 112 of the routed andattached mechanical cables 104 are temporarily stowed prior to shipmentto reduce tangling of the cables 104 and improve assembly process in anassembled state of the seat module 100 where the seat module 100 issecurely mounted to the cushion frame 14 of the seat unit 10. In theassembled state of the seat module 100, as shown in FIG. 1 , the stowedend portions 112 of the mechanical control cables 104 are released(un-stowed) from the stowing features 114 of the module plate 102 andeach connected to the mechanical parts 16 such as the levers and latchsystems for the seat actuation as needed.

The stowing feature 114 is formed in at least one location of the moduleplate. As shown in FIGS. 2 and 4 , for example, the stowing features 114are formed in two locations of the module plate 102. The stowingfeatures 114 are also formed as a mechanical-lock type such as asnap-fit or a press-fit for releasably retaining the end portion 112 ofeach of the mechanical control cables 104. In the seat module 100, theend portions 112 of the attached mechanical control cables 104 aretemporarily retained in the stowing features 114 of the module plate 102in the pre-assembled state before connecting to the mechanical parts 16of the seat unit 10. In the assembled state, the seat module 100 isattached to the cushion frame 14 of the seat unit 10 via the mountingfeatures 108 of the module plate 102. While the seat module 100 havingthe stowed end portions 112 of the mechanical control cables 104 issecurely mounted to the seat unit 10, the end portions 112 of themechanical control cables 104 are retained in the stowing feature 114,and in the assembled state of the seat module 100 after the seat module100 is mounted to the seat unit 10, the stowed end portions 112 of themechanical control cables 104 are un-stowed (released) and connected tothe mechanical parts 16 such as the levers and latch systems of the seatunit 10.

FIGS. 3 and 4 show examples of the routed and attached mechanicalcontrol cables 104 in the pre-assembled state of the seat module 100.When the cable bundle housing 106 with the mechanical control cables 104is coupled to the module plate 102, the mechanical control cables 104are routed and attached to the module plate 102. Some cables 103 of theattached mechanical control cables 104 rotate clockwise and the endportions 112 of the cables 103 are temporarily stowed in one of thestowing features 114 of the module plate 102. While the mechanicalcontrol cables 104 are attached to the module plate 102, at least oneportion of each of the mechanical control cables 104 is held by theretention features 110 formed on the module plate 102. Other cables 105of the attached mechanical control cables 104 rotate counter-clockwiseand also the end portions 112 of the cables 105 are temporarily stowedin one of the stowing features 114 formed in the module plate 102. Inaddition, as described above, at least one portion of the cables 104 isheld by the retention features 110 of the module plate 102.

As shown in FIG. 4 , accordingly, the seat module 100 having themechanical control cables 104 routed and attached to the module plate102 in the pre-assembled state is configured to prevent the mechanicalcontrol cables 104 from tangling and allow the mechanical control cables104 to be easily connected to the mechanical parts 16 when the seatmodule 100 is mounted to the seat unit 10 in the assembled state.Specifically, the seat module 100 according to this embodiment reducesthe assembly time including the laying work and also the number of thecomponents such as zip-ties or brackets for attaching each of theseparate mechanical control cables 104 to the seat unit 10.

Referring to FIGS. 5 and 5A, the module plate 102 further includes aloom 116 protruding from a side of the module plate 102. The loom 116 islocated in at least one location of the module plate 102 and configuredto retain a portion of the mechanical control cables 104. In FIG. 5 ,one of the attached mechanical control cables 104 is quite long andloops in a complete circle on the underside of the module plate 102. Theprotruded loom 116 at the side of the module plate 102 is used to retaina portion of the long looped control cable 104. In addition, when thereis no place on the upper side of the module plate 102 to accommodate themechanical control cables 104, the cables 104 are looped on an undersideof the module plate 102 (see dashed-lines in FIG. 5 ) for preventing thetangling of the cables 104 in the pre-assembled state. According toother forms of the present disclosure, the loom is configured totemporarily retain a long mechanical control cable for connecting theend portion of the long mechanical control cable to another mechanicalpart, which is located far from the mounted seat module 100 (ex. anupper side of the seatback frame) such that the protruded loom 116prevents the attached long mechanical control cables from tanglingbefore mounting to the seat unit 10 in the pre-assembled state andallows the cables to easily release (un-stow) and connect to one of themechanical parts 16 in the seatback frame in the assembled state.

As shown in FIGS. 4 and 4A, the end portions 112 of the mechanicalcontrol cables 104 are generally snapped in the stowing features 114 ofthe module plate 102 for reducing tangling of the mechanical controlcables 104 in the pre-assembled state. According to another exemplaryform of the present disclosure, a different method for temporarilystowing the end portion 112 of the mechanical control cable 104 is alsoillustrated in FIGS. 4 and 4B. In the pre-assembled state of the seatmodule 100, the end portion 112 of one of the mechanical control cables105 attached to the module plate 102 is temporarily stowed by tuckingunder or above one of the other cables 103 as shown in FIG. 4B. Afterthe seat module 100 is attached to the seat unit 10, the stowed end ofthe mechanical control cables 104 by tucking is un-stowed (released) andconnected to a predetermined mechanical parts 16 of the seat unit 10 inthe assembled state as shown in FIG. 1 . Accordingly, in thepre-assembled state of the seat module 100, the end portions 112 of themechanical control cables 104 are temporarily stowed by either thestowing feature 114 formed on the module plate 102 or tucking under orabove the other cables 104 for reducing tangling and improving assemblywith the seat unit 10.

In addition, FIG. 4 illustrates the detailed mechanical control cables104. Each of the mechanical control cables 104 includes a pad 120, anadjuster 122, a spring 124, a clip 126 or any other typical controlcable components for controlling the mechanical parts 16 of the seatunit 10. In the seat module 100, accordingly, the assembled mechanicalcontrol cables 104 with the control cable components including the pad120, the adjuster 122, the spring 124, a clip 126, etc. are routed andattached to the module plate 102.

Furthermore, as shown in FIG. 1 , the seat module 100 may be applied asa trim surface of the seat unit 10. In FIG. 1 , the mounted seat module100 under the seat cushion is configured to be a part of the trimsurface of the lower part of the seat unit 10. In the assembled state,the attached seat module 100 in the seat unit 10 may be a part of theclass-A surface such that an original trim piece used in the base of thecushion frame 14 for cosmetic purposes is replaced with the attachedseat module 100. Accordingly, the attached module plate 102 having themechanical control cables 104 under the cushion is used as the class-Asurface of the seat unit 10, so that it effectively reduces the weightand assembly time including the manufacturing costs.

While the above description constitutes the preferred embodiments of thepresent invention, it will be appreciated that the invention issusceptible to modification, variation and change without departing fromthe proper scope and fair meaning of the accompanying claims.

What is claimed is:
 1. A seat module adapted to be attached to a seathaving components for seat actuation in a motor vehicle, the seat modulecomprising: at least one operating cable; and a module plate formed witha mounting feature for attaching to the seat and a retention feature forretaining the at least one operating cable, wherein the operating cableis retained in the module plate in a pre-assembled state where theoperating cable is retained by the module plate in a stowed condition,and the operating cable is released from the stowed condition andconnected to the components of the seat in an assembled state where themodule plate retaining the operating cable is attached to the seat. 2.The seat module of claim 1, wherein, in the pre-assembled state, atleast one portion of the operating cable is temporarily retained by themodule plate while the module plate is attached to the seat, and in theassembled state, the at least one portion of the operating cable isreleased for connecting to the components of the seat.
 3. The seatmodule of claim 1, wherein the module plate includes at least oneretention feature formed as a mechanical-lock type and located in atleast one location of the module plate for retaining the operating cablein both of the pre-assembled state and the assembled state.
 4. The seatmodule of claim 1, wherein the module plate includes at least onestowing feature formed and located in at least one location of themodule plate for temporarily stowing at least one portion of theoperating cable in the stowed condition.
 5. The seat module of claim 4,wherein the stowing feature is formed with a mechanical-lock type forreleasably retaining the at least one portion of the operating cable. 6.The seat module of claim 1, wherein, in the pre-assembled state, atleast one portion of the operating cable is placed in the stowedcondition by tucking under or above one of the operating cables retainedin the module plate.
 7. The seat module of claim 1, wherein the moduleplate further includes a loom for temporarily stowing at least oneportion of the operating cable in the pre-assembled state.
 8. The seatmodule of claim 1, wherein the module plate is formed of a resinmaterial or a composite material such as a glass woven plastic compositesheet.
 9. The seat module of claim 1, wherein the operating cable is amechanical control cable having a terminal end connected to one ofmechanical parts for the seat actuation.
 10. The seat module of claim 9,wherein the mechanical control cable formed with a core and a sheathincludes a pad, an adjuster, a spring, and a clip to facilitate theconnection with the mechanical parts.
 11. A method for producing a motorvehicle seat structure having components for seat actuation, the methodcomprising the steps of: providing at least one operating cable,providing a module plate adapted to be attached to a portion of the seatstructure; retaining the operating cable in a stowed condition in atleast one location of the module plate, thereby producing a seat modulesubassembly in a pre-assembled state of the seat module; attaching theseat module subassembly to a portion of the seat structure; andconnecting the operating cable to the components of the seat byreleasing the operating cable from the stowed condition whereby the seatmodule is placed in an assembled state.
 12. The method of claim 11,providing the module plate with a retention feature formed as amechanical-lock type and located in the at least one location of themodule plate for coupling with the operating cable in both thepre-assembled state and the assembled state.
 13. The method of claim 11,providing the module plate formed with a mounting feature in at leastone location of the module plate to attach the seat module subassemblyto the seat structure.
 14. The method of claim 11, wherein the at leastone portion of the operating cable is stowed in the stowed condition byproviding a stowing feature formed in the module plate in the seatmodule subassembly.
 15. The method of claim 11, wherein the at least oneportion of the operating cable is placed in the stowed condition bytucking under or above one of the operating cables retained in themodule plate in the seat module subassembly.
 16. The method of claim 11,wherein the at least one portion of the operating cable is placed in thestowed condition in a loom formed in the module plate in the seat modulesubassembly.
 17. The method of claim 11, wherein the operating cable isa mechanical control cable having a terminal end connected to one ofmechanical parts for the seat actuation.
 18. The seat module of claim17, wherein the mechanical control cable formed with a core and a sheathincludes a pad, an adjuster, a spring, or a clip to facilitate theconnection with the mechanical parts.